A method for improving substrate degradation in agricultural biogas plants

Abstract

 The invention relates to the use of at least one bacterial amylase and/or bacterial or fungal cellulase in combination with one or more protease(s) in substrates for anaerobic digestion processes for biogas production for improving degradation of maize, maize silages and/or other biogas substrates, in particular for improving gas yield, velocity and substrate conversion rate.

Description

Field of the Invention

[0001] The invention concerns the production of biogas, which gains more and more in importance in economy. Biogas is produced by anaerobic microbiological degradation of liquid manure, energy plants (maize, grain), agricultural by-products or organic waste. It consists mainly of CH₄ and CO₂. CH₄ (share normally more than 50%) is used for the production of thermal and electrical energy. About 11 % of the renewable energy is produced by the use of biogas in Germany (2009).

[0002] Modern biogas plants are equipped with industrial process measurement and control devices. Additives, such as trace element or enzyme preparations, are often used to optimize the biological process of anaerobic digestion. These additives can enhance metabolic action of the microorganisms or ameliorate substrate degradation. In the past, the application of carbohydrate-degrading enzyme preparations (carbohydrases) has been shown to be beneficial for the break-down of cellulose or hemicellulose in plant material to simple sugars. The resulting sugars are subsequently metabolized by acidogenic and acetogenic bacteria to acetic acid, H₂ and CO₂. These compounds are the substrates for methane production by methanogenic archea. Hence, beneficial effects on plant cell wall degradation are often reflected in increased biogas yields, reduced substrate input or reduced viscosity.

[0003] The invention is especially interesting for biogas plants, which are run entirely or to a large extent on renewable primary products, such as corn silage, grass silage or other whole plant silages. The utilization of recalcitrant substrates with high fiber contents, which is propagated for the production of second generation biofuels, makes the need for enzymatic additives more urgent. This is because the degradation of fiber-rich substrates is slow and incomplete. Furthermore, many biogas plants, which run on plant material alone, have C:N ratios outside the suggested range of 20 to 30. That is to say, the nitrogen content in many agricultural biogas plants is too low and, hence, the performance of microorganisms is suboptimal.

Description of the Related Art

[0004] There are several publications concerning the biogas production, see for instance the survey Biomethanation I and II (Advances in Biochemical Engineering/Biotechnology; volumes 81 and 82, Springer-Verlag Berlin Heidelberg GmbH, 2003).

[0005] Many patents protect the production of biogas in biogas plants supported by enzymatic substrate degradation, some examples are given below.

[0006] In DE 4141832 (S. R. Dauber, priority date: 18.12.1991) the novelty is a waste water treatment process and apparatus, which treats de-watered sludge. It consists of a mixture of activated sludge from a settlement tank and primary sludge. Further, it is described that the plant incorporates an anaerobically-operated acidification reactor, followed by an anaerobically-operated biogas reactor with the following features:

(a) Protease, amylase, lipase, cellulase or mixtures thereof are introduced into the acidification reactor,

(b) The acidification reactor is operated in the temperature range 20 to 70°C in a pH range of 3.5 to 6.5.

(c) The temperature and the pH value are set in the ranges as stated (b) above.

[0007] Later on, the German application DE102004042688 (Biopract GmbH, priority date 01.09.2004) was published. It describes the acceleration of rotting and increasing gas production in waste water purification and biogas plants by adding mixed enzyme preparation to clarified sludge before entering gas-producing reactor. The enzyme preparation consists of one or more carboxyhydrases together with other hydrolyzing enzymes such as lipases and proteases.

[0008] In the years 2010/2011, some WO patent specifications of the Danish company Novozymes A/S were published.

• WO/2013/083801 (Title: Biogas from substrates comprising animal manure and enzymes) contains a biogas production process comprising the steps of providing a substrate comprising manure, and
  (a) adding one or more enzyme to the substrate, and then adding the substrate with the one or more enzyme to a biogas digester; or

  (b) adding the substrate to a digester tank and adding one or more enzyme to the tank. The enzymes are selected from amylolytic enzymes, lipolytic enzymes, proteolytic enzymes, cellulolytic enzymes, oxidoreductases and plant cell-wall degrading enzyme.
• WO 2012093041 A1 (Title: Process for producing biogas from pectin and lignocellulose containing material) relates to biogas production processes with enzymatic pre-treatment, said processes comprising the steps of providing a slurry comprising a lignocellulose- and pectin-containing material, water and two or more enzyme treatments; allowing the two or more enzyme-treatment steps to degrade the lignocellulose- and pectin-containing material, and adding the degraded material to a biogas digester tank at a suitable rate and ratio to effectively convert the material to biogas in the digester.
• WO 2011092136 (Title: Biogas production process with enzymatic pre-treatment) contains a biogas production process with enzymatic pre-treatment; said process comprising the steps of providing a slurry comprising a lignocellulose-containing material, water and one or more enzyme; allowing the one or more enzyme to degrade the lignocellulose-containing material at a suitable temperature and pH; and adding the enzyme-degraded material to a biogas digester tank at a suitable rate and ratio to effectively convert the material to biogas in the digester.

Objective of the invention

[0009] The general objective of the invention is to enhance the yield of biogas in decomposition processes.

[0010] It is the goal of the present invention to provide a preferably improved alternative to the carbohydrase preparations, which are currently used in biogas plants. These products are supposed to improve degradation of plant material, to increase the gas yield or the speed of gas formation and/or to reduce viscosity in the fermenter.

Summary of invention

[0011] It has now been found surprisingly that the combined use of an amylase and/or a NSP (Non-Starch-Polysaccharide)-degrading enzyme mixture with one or more proteolytic enzyme(s) results in the elevation of the total biogas yield and the speed of degradation of substrates, such as corn silage, grass silage, triticale silage and/or other whole-plant silages. So far, there was no indication that the proteolytic capacity of the microbiota in biogas fermenters can be a limiting factor. If such an important activity was limited, this is an explanation of the observed synergistic effect of carbohydrases combined with one or more proteases.

[0012] Lately, it was found in lab experiments that the supplementation of carbohydrases with proteolytic enzymes further enhances the rate of biogas production. There are at least two possible explanations for this observation.

[0013] The first is that protein-carbohydrate complexes are cleaved, such as prolamin-starch complexes in maize kernels. This cleavage leads to the liberation of starch, which is otherwise shielded by prolamin, and can then be degraded by hydrolyzing bacteria. This leads to a higher amount of digestible carbohydrates and, subsequently, to a higher gas production.

[0014] The second explanation for the observed enzyme effect is that an enzymatic cleavage of proteins in the substrate results in peptides and amino acids. These compounds may be utilized by microorganisms as nitrogen source, which is crucial for the synthesis of all enzymes necessary in their metabolisms. A higher metabolic activity of the microbiota will then lead to a more efficient or faster biogas production.

[0015] In particular, the inventors of the present invention have found that the addition of a protease in combination with a carbohydrase, as for example an amylase or a NSP-degrading enzyme, results in a significant boost of the carbohydrase induced degradation and, hence, in the rate of gas production in the anaerobic biogas fermentation.

[0016] In a further embodiment, the invention relates to a method for improving the degradation of maize, maize silages and other whole-plant silages as substrate in anaerobic digesters by treating the substrate with an efficient amount of one or more proteolytic enzymes in combination with at least one carbohydrase.

Detailed Description of the Invention

[0017] In the present context, a carbohydrase is an enzyme that catalyzes the breakdown of carbohydrates into simple sugars.

[0018] Examples of carbohydrases useful in the present context are glucanases, in particular beta-glucanases and xyloglucanases, cellulases, xylanases, amylases and pectinases and mixtures thereof. In a preferred embodiment of the invention, the carbohydrases are amylase and cellulase.

[0019] The carbohydrase for use according to the invention is stable in the presence of protease. The protease stability may be determined by incubating 0.5 mg purified carbohydrase enzyme protein/ml in a buffer at a desired pH (e.g. pH 3, 4, or 5), for the desired time (e.g. 30, 45, 60, 90, or 120 minutes) in the presence of protease (e.g. pepsin, 70 mg/l), and then raising pH to the desired pH (e.g. pH 4, 5, 6, 7, or 8) and measuring residual activity. The residual carbohydrase activity is preferably at least 20%, preferably at least 30, 40, 50, 60, 70, 80, or at least 90% relative to the control (a non-protease-treated sample).

[0020] In a particular embodiment at least one carbohydrase is an amylase, a cellulase or an enzyme mixture comprising at least one enzyme selected from the group consisting of beta-glucanases, xyloglucanases, xylanases, amylases and pectinases.

[0021] In the present context, an amylase is an enzyme that catalyzes the endo-hydrolysis of starch and other linear and branched oligo- and polysaccharides. In a particular embodiment, the amylase for use according to the invention has alpha-amylase activity, which catalyzes the endohydrolysis of 1,4-alpha-glucosidic linkages in oligosaccharides and polysaccharides. Alpha-amylases act, e.g., on starch, glycogen and related polysaccharides and oligosaccharides in a random manner, liberating reducing groups in the alpha-configuration.

[0022] In a preferred embodiment the amylase of the invention is an alpha-amylase (systematical name: 1,4-alpha-D-glucan glucanohydrolase), preferably a bacterial amylase. In further embodiments, the amylase of the invention belongs to the EC 3.2.1.-group of amylases, such as EC 3.2.1.1 (alpha-amylase), EC 3.2.1.2 (beta-amylase), EC 3.2.1.3 (glucan 1,4-alpha-glucosidase, amyloglucosidase, or glucoamylase), EC 3.2.1.20 (alpha-glucosidase), EC 3.2.1.60 (glucan 1,4-alpha-maltotetraohydrolase), EC 3.2.1.68 (isoamylase), EC 3.2.1.98 (glucan 1,4-alpha-maltohexosidase), or EC 3.2.1.133 (glucan 1,4-alpha-maltohydrolase).

[0023] In a preferred embodiment, the amylase for use according to the invention can be, or is, classified as belonging to the EC 3.2.1.1 group. The EC numbers refer to Enzyme Nomenclature 1992 from NC-IUBMB, Academic Press, San Diego, California, including supplements 1-5 published in Eur. J. Biochem. 1994, 223, 1-5; Eur. J. Biochem. 1995, 232, 1-6; Eur. J. Biochem. 1996, 237, 1-5; Eur. J. Biochem. 1997, 250, 1-6; and Eur. J. Biochem. 1999, 264, 610-650; respectively. The nomenclature is regularly supplemented and updated; see e.g. the World Wide Web at http://www.chem.qmw.ac.uk/iubmb/enzyme/index.html.

[0024] Amylase activity may be determined by any suitable assay. Generally, assay-pH and assay-temperature may be adapted to the enzyme in question. Examples of assay-pH-values are pH 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12. Examples of assay-temperatures are 30, 35, 37, 40, 45, 50, 55, 60, 65, 70, 80, 90, or 95°C. Preferred pH values and temperatures are in the physiological range, such as pH values of 3, 4, 5, 6, 7, or 8, and temperatures of 30, 35, 37, or 40°C. The following amylase assay can be used: Substrate: Phadebas tablets (Pharmacia Diagnostics; cross-linked, insoluble, blue-coloured starch polymer, which is mixed with bovine serum albumin and a buffer substance, and manufactured into tablets). Assay Temperature: 37°C. Assay pH: 4.3 (or 7.0, if desired). Reaction time: 20 min. After suspension in water the starch is hydrolyzed by the alpha-amylase, giving soluble blue fragments. The absorbance of the resulting blue solution, measured at 620 nm, is a function of the alpha-amylase activity. One Fungal alpha-Amylase Unit (1 FAU) is the amount of enzyme which breaks down 5.26 g starch per hour at the standard assay conditions. A preferred starch is Merck, Amylum solubile Erg. B. 6, Batch 9947275. A more detailed assay description, APTSMYQI-3207, is available on request from Novozymes A/S, Krogshoejvej 36, DK-2880 Bagsvaerd, Denmark.

[0025] For a taxonomical classification and identification of bacteria reference is made to Bergey's Manual of Systematic Bacteriology (1986), vol 2, ISBN0-683-0783. In the alternative, the well-known 16SrRNA sequence analysis can be used (see e.g. Johansen et al, Int. J. Syst. Bacteriol, 1999, 49, 1231-1240, in particular the Methods section on p. 1233, 2^nd column); or taxonomy experts can be consulted, e.g. from DSMZ or other recognized depositary institutes.

[0026] As employed herein the term bacterial designates amylases that are derived from bacteria. The term "derived from" includes enzymes obtainable, or obtained, from wild type bacterial strains, as well as variants thereof. The variants may have at least one substitution, insertion, and/or deletion of at least one amino acid residue. The term variant also includes shufflants, hybrids, chimeric enzymes and consensus enzymes. The variants may have been produced by any method known in the art, such as site-directed mutagenesis, random mutagenesis, consensus derivation processes (EP 897985), and gene shuffling (WO 95/22625, WO 96/00343), etc. For the present purposes an amylase variant qualifies as bacterial when at least one bacterial amylase has been used for its design, derivation or preparation. The term bacterial does not refer to a potential recombinant production host but only to the origin of the amylase encoding gene that is hosted by it.

[0027] The amylase for use according to the invention is preferably derived from a strain of Bacillus, such as strains of Bacillus amyloliquefaciens, Bacillus circulans, Bacillus halmapalus, Bacillus licheniformis, Bacillus megaterium, Bacillus sp., Bacillus stearothermophilus, and Bacillus subtilis; preferably from strains of Bacillus amyloliquefaciens, Bacillus halmapalus, Bacillus licheniformis, Bacillus sp., Bacillus subtilis, and Bacillus stearothermophilus.

[0028] Non-limiting examples of wildtype amylases for use according to the invention are those derived from Bacillus licheniformis, such as Swissprot entry name AMY_BACLI, primary accession number P06278; Bacillus amyloliquefaciens, such as Swissprot entry name AMY_BACAM, primary accession number P00692; Bacillus megaterium, such as Swissprot entry name AMY_BACME, primary accession number P20845; Bacillus circulans, such as Swissprot entry name AMY_BACCI, primary accession number P08137; Bacillus stearothermophilus, such as Swissprot entry name AMY_BACST, primary accession number P06279. Another example is from Bacillus subtilis, such as Swissprot entry name AMY_BACSU, primary accession number P00691.

[0029] For purposes of the present invention, preferred amylases are the amylases contained in the following commercial products: BAN, Stainzyme, Termamyl SC, Natalase, and Duramyl (all from Novozymes), and in the Validase BAA and Validase HT products (from Valley Research). Further particular examples of amylases for use according to the invention are the amylases contained in the following commercial products: Clarase, DexLo, GC 262 SP, G-Zyme G990, G-Zyme G995, G-Zyme G997, G-Zyme G998, HTAA, Optimax 7525, Purastar OxAm, Purastar ST, Spezyme AA, Spezyme Alpha, Spezyme BBA, Spezyme Delta AA, Spezyme DBA, Spezyme Ethyl, Spezyme Fred (GC521), Spezyme HPA, and Ultraphlow (all from Genencor); Validase HT340L, Valley Thin 340L (all from Valley Research); Avizyme 1500, Dextro 300 L, Kleistase, Maltazyme, Maxamyl, Thermozyme, Thermatex, Starzyme HT 120 L, Starzyme Super Conc, and Ultraphlo.

[0030] In a particular embodiment, the amylase for use according to the invention is pelleting stable, and/or thermostable. The melting temperature (Tm) of an enzyme is a measure of its thermostability. The amylase of the invention may have a Tm of at least 75°C, 76°C, 77°C, 78°C, 79°C, 80°C, 81 °C, 82°C, 83°C, 84°C, 85°C, 86°C, 87°C, 88°C, 89°C, 90°C, 91°C, 92°C, 93°C, 94°C or at least 95°C, as determined by Differential Scanning Calorimetry (DSC). The DSC is performed in a 10 mM sodium phosphate, 50 mM sodium chloride buffer, pH 7.0. The scan rate is constant, e.g. 1.5°C/min. The interval scanned may be from 20 to 100°C. Another buffer may be selected for the scanning, e.g. a buffer of pH 5.0, 5.5, 6.0, or pH 6.5. In further alternative embodiments, a higher or lower scan rate may be used, e.g. a lower one of 1.4°C/min, 1.3°C/min, 1.2°C/min, 1.1°C/min, 1.0°C/min, or 0.9°C/min.

[0031] In another preferred embodiment, the amylase for use according to the invention has an activity at pH 7.0 and 37°C of at least 35% relative to the activity at the pH-optimum and 37°C. More preferably, the activity at pH 7.0 and 37°C is at least 40, 45, 50, 55, 60, 65, 70, or at least 75% of the activity at the pH-optimum and 37°C.

[0032] In another preferred embodiment, the amylase of the invention has an activity at pH 7.0 and 37°C and in the presence of 5mM bile salts of at least 25% relative to the activity at the pH-optimum and 37°C in the absence of bile salts. More preferably, the activity at pH 7.0 and 37°C and in the presence of 5mM bile salts is at least 30, 35, 40, 45, 50, 55, 60, or at least 65% of the activity at the pH-optimum and 37°C in the absence of bile salts.

[0033] A commercially available bacterial amylase for use according to the present invention is RumiStar^® (DSM Nutritional Products AG).

[0034] Other relevant carbohydrases are NSP-hydrolysing enzymes, such as glucanases, in particular beta-glucanases and xyloglucanases, cellulases, xylanases and pectinases.

[0035] In the present context, a cellulase is an enzyme that catalyzes the hydrolysis of cellulose. In a preferred embodiment the cellulase of the invention is (systematical name: 4-β-D-glucan 4-glucanohydrolase) preferably a fungal cellulase. In further embodiments, the celluase of the invention belongs to the EC 3.2.1.- group glycosidases, i.e. enzymes hydrolysing O- and S-glycosyl compounds, such as EC 3.2.1.4 (cellulase), EC 3.2.1.6, EC 3.2.1.14, EC 3.2.1.21, EC 3.2.1.73, EC 3.2.1.74, EC 3.2.1.91, EC 3.2.1.151, EC 3.2.1.165, EC 3.2.1.176. In a particular embodiment, cellulase catalyzes the endohydrolysis of (1→4)-β-D-glucosidic linkages in cellulose and other oligosaccharides and polysaccharides. Cellulases act, e.g., on cellulose and related polysaccharides and oligosaccharides in a random manner, liberating reducing groups in the alpha-configuration.

[0036] The EC numbers refer to Enzyme Nomenclature 1992 from NC-IUBMB, Academic Press, San Diego, California, including supplements 1-5 published in Eur. J. Biochem. 1994, 223, 1-5; Eur. J. Biochem. 1995, 232, 1-6; Eur. J. Biochem. 1996, 237, 1-5; Eur. J. Biochem. 1997, 250, 1-6; and Eur. J. Biochem. 1999, 264, 610-650; respectively. The nomenclature is regularly supplemented and updated; see e.g. the World Wide Web at http://www.chem.qmw.ac.uk/iubmb/enzyme/index.html.

[0037] Commercially available fungal cellulase preparations for use according the present invention are MethaPlus^®, Axiase™ (DSM), ZyMaxx and JBS.

[0038] In the present context, a beta-glucanase is an enzyme that catalyzes the endohydrolysis of linkages in beta-D-glucans (E.C.3.2.1.4, E.C.3.2.1.6, E.C.3.2.1.39, E.C.3.2.1.58, E.C.3.2.1.71, E.C.3.2.1.73, E.C.3.2.1.74, E.C.3.2.1.75, E.C.3.2.1.91, E.C.3.2.1.151, E.C.3.2.1.155 and E.C.3.2.1.176). Substrates include laminarin, lichenin, cereal D-glucans and others.

[0039] In the present context, a xyloglucanase is an enzyme that catalyzes reaction involves endohydrolysis of 1,4-beta-D-glucosidic linkages in xyloglucan with retention of the beta-configuration of the glycosyl residues (E.C.3.2.1.151)

[0040] In the present context, a xylanase is an enzyme that catalyzes the xylosidic linkage in xylans. This enzymatic activity can be found in the enzyme classes E.C.3.2.1.8, E.C.3.2.1.32, E.C.3.2.1.136 and E.C.3.2.1.156.

[0041] In the present context, a pectinase is an enzyme that catalyzes the random hydrolysis of (1->4)-alpha-D-galactosiduronic linkages in pectate and other galacturonans (E.C.3.2.1.15)

[0042] The EC numbers refer to Enzyme Nomenclature 1992 from NC-IUBMB, Academic Press, San Diego, California, including supplements 1-5 published in Eur. J. Biochem. 1994, 223, 1-5; Eur. J. Biochem. 1995, 232, 1-6; Eur. J. Biochem. 1996, 237, 1-5; Eur. J. Biochem. 1997, 250, 1-6; and Eur. J. Biochem. 1999, 264, 610-650; respectively. The nomenclature is regularly supplemented and updated; see e.g. the World Wide Web at http://www.chem.qmw.ac.uk/iubmb/enzyme/index.html.

[0043] Proteases, or peptidases, catabolize peptide bonds in proteins breaking them down into fragments of amino acid chains, or peptides.

[0044] Proteases are classified on the basis of their catalytic mechanism into the following groups: serine proteases, EC 3.4.21.-, (S), cysteine proteases (C), aspartic proteases (A), metalloproteases (M), and unknown, or as yet unclassified, proteases (U), see Handbook of Proteolytic Enzymes, A. J. Barrett, N. D. Rawlings, J. F. Woessner (eds), Academic Press (1998), in particular the general introduction part.

[0045] Proteases for use according to the invention are acid stable proteases.

[0046] In a particular embodiment, the protease for use according to the invention is a microbial protease, the term microbial indicating that the protease is derived from, or originates from a microorganism, or is an analogue, a fragment, a variant, a mutant, or a synthetic protease derived from a microorganism. It may be produced or expressed in the original wild-type microbial strain, in another microbial strain, or in a plant; i. e. the term covers the expression of wild-type, naturally occurring proteases, as well as expression in any host of recombinant, genetically engineered or synthetic proteases. Examples of microorganisms are bacteria, e. g. bacteria of the phylum Actinobacteria phy. nov., e. g. of class I: Actinobacteria, e. g. of the Subclass V: Actinobacteridae, e. g. of the Order I: Actinomycetales, e. g. of the Suborder XII: Streptosporangineae, e. g. of the Family II: Nocardiopsaceae, e. g. of the Genus I: Nocardiopsis, e. g. Nocardiopsis sp. NRRL 18262, and Nocardiopsis alba ; e.g. of the species Bacillus or mutants or variants thereof exhibiting protease activity. This taxonomy is on the basis of Berge's Manual of Systematic Bacteriology, 2nd edition, 2000, Springer (preprint: Road Map to Bergey's).

[0047] Preferred proteases according to the invention are acid stable serine proteases derived from Nocardiopsis dassonvillei subsp. dassonvillei DSM 43235 (A1918L1), Nocardiopsis prasina DSM 15649 (NN018335L1), Nocardiopsis prasina (previously alba) DSM 14010 (NN18140L1), Nocardiopsis sp. DSM 16424 (NN018704L2), Nocardiopsis alkaliphila DSM 44657 (NN019340L2) and Nocardiopsis lucentensis DSM 44048 (NN019002L2), as well as homologous proteases.

[0048] The term serine protease refers to serine peptidases and their clans as defined in the above Handbook. In the 1998 version of this handbook, serine peptidases and their clans are dealt with in chapters 1-175. Serine proteases may be defined as peptidases in which the catalytic mechanism depends upon the hydroxyl group of a serine residue acting as the nucleophile that attacks the peptide bond. Examples of serine proteases for use according to the invention are proteases of Clan SA, e. g. Family S2 (Streptogrisin), e. g. Sub-family S2A (alpha-lytic protease), as defined in the above Handbook.

[0049] Protease activity can be measured using any assay, in which a substrate is employed, that includes peptide bonds relevant for the specificity of the protease in question. There are no limitations on the origin of the acid stable serine protease for use according to the invention. Thus, the term protease includes not only natural or wild-type proteases, but also any mutants, variants, fragments etc. thereof exhibiting protease activity, as well as synthetic proteases, such as shuffled proteases, and consensus proteases. Such genetically engineered proteases can be prepared as is generally known in the art, e. g. by Site-directed Mutagenesis, by PCR (using a PCR fragment containing the desired mutation as one of the primers in the PCR reactions), or by Random Mutagenesis. The preparation of consensus proteins is described in e. g. EP 0 897 985.

[0050] Examples of acid-stable proteases for use according to the invention are proteases derived from Nocardiopsis sp. NRRL 18262, and Nocardiopsis alba and proteases of at least 60, 65, 70, 75, 80, 85, 90, or at least 95% amino acid identity to any of these proteases.

[0051] For calculating percentage identity, any computer program known in the art can be used. Examples of such computer programs are the Clustal V algorithm (Higgins, D. G., and Sharp, P. M. (1989), Gene (Amsterdam), 73, 237-244 ; and the GAP program provided in the GCG version 8 program package (Program Manual for the Wisconsin Package, Version 8, Genetics Computer Group, 575 Science Drive, Madison, Wisconsin, USA 53711) (Needleman, S. B. and Wunsch, C. D., (1970), Journal of Molecular Biology, 48, 443-453.

[0052] In another particular embodiment, the protease for use according to the invention, besides being acid-stable, is also thermostable.

[0053] The term thermostable means for proteases one or more of the following: That the temperature optimum is at least 50 °C, 52 °C, 54 °C, 56 °C, 58 °C, 60 °C, 62 °C, 64 °C, 66 °C, °68 C, or at least °70 C.

[0054] A commercially available serine proteases derived from Nocardiopsis is Ronozyme^®ProAct^® (DSM Nutritional Products AG).

[0055] In a particular embodiment, the amylase and the protease, in the form in which they are added to the substrate, or when being included in a substrate additive, are well-defined. Well-defined means, that the enzyme preparation is at least 50% pure on a protein-basis. In other particular embodiments the enzyme preparation is at least 60, 70, 80, 85, 88, 90, 92, 94, or at least 95% pure. Purity may be determined by any method known in the art, e.g. by SDS-PAGE, or by Size-exclusion chromatography (see Example 12 of WO 01/58275).

[0056] A well-defined enzyme preparation is advantageous. For instance, it is much easier to dose correctly to the substrate an enzyme that is essentially free from interfering or contaminating other enzymes. The term dose correctly refers in particular to the objective of obtaining consistent and constant results, and the capability of optimising dosage based upon the desired effect.

[0057] Enzyme preparations with purities of this order of magnitude are in particular obtainable using recombinant methods of production, whereas they are not so easily obtained and also subject to a much higher batch-to-batch variation when produced by traditional fermentation methods.

[0058] In the use according to the invention, the enzyme combinations described above can be added to the biogas fermenter before, after, or simultaneously with the substrate. The latter is preferred. This applies to both, liquid and solid formulations. The dosage has to be adapted to the respective biogas fermenter.

[0059] The application of enzyme preparations, which contain proteolytic and carbohydrolytic enzyme activities, was shown to boost biogas production by more than 10%. Possible reasons for this significant enhancing effect and some advantages of using enzyme additives with the described, combined lead activities in biogas plants over the supplementation with commercially available products are as follows:

First, the addition of carbohydrase-protease preparations catalyzes the cleaving of protein-carbohydrate complexes (e.g. prolamin-starch complexes in maize kernels), which results in the liberation of simple sugars as a carbon source and peptides as a nitrogen source. The incorporation of short peptides or amino acids during the microbial protein synthesis is more favorable than the synthesis of proteins from other nitrogen compounds, such as NH₄⁺. Raising the nitrogen availability is expected to lead to higher metabolic activities of the microbiota. This should generally lead to higher biogas yields. Also, because enzymes are catalysts, they are generally not consumed in the reaction they catalyze. Therefore, it is expected that their actions last for a longer period of time without a significant nitrogen accumulation in the digestate.

[0060] The present invention is further described by the following examples which should not be construed as limiting the scope of the invention.

Examples

[0061] Chemicals used as buffers and substrates were commercial products of at least reagent grade.

Example 1: Modified batch test based on VDI 4630

Target:

[0062] The aim of the investigations is to determine the cumulative normalized gas volume produced from a chosen substrate by an anaerobic microbial culture. Gas produced is determined via the measurement of gas pressure due to accumulating gas volume in the head space of the fermentation vessel. Fermentation conditions are described as a so called headspace test.

Method:

[0063] The test is a 15 ml batch fermentation carried out in 50 ml vessels in the following manner:

In two independent experiments, 4 replicates of the batches are cultivated over 21 days at 39°C. At start time (to) each fermentation bottle, except the controls, contains 15 ml of a described anaerobic culture, a substrate and an additive. Controls do not contain the active, enzymatic additive. They may contain inactive additives, such as the stabilizing matrix of the respective enzyme preparation or no additive at all. Gas pressure in the head space, which is the result of gas formation during fermentation, is measured once per day in the first week, every second day in the second week and every third day in the last week. Normalized gas formation is calculated and compared to corresponding controls.

[0064] Fermentations are carried out in so-called headspace bottles (Rollrandflaschen) ND20, 50 ml, No. 1 400 118 LA, Burdich Laborbedarf GmbH & Co. KG with 20 mm aluminum caps with septum No. 1 400 711. It is necessary, to measure the bottle volume very accurately. Then it is possible to calculate head space volume very exact. Vessel volume is measured via mass determination with distilled water. Weight has to be determined exactly down to four significant digits after the decimal point. The experimental procedure is as follows: For every single experimental variant four vessels (labelled, exact volume known) including caps and septa have to be prepared. The weight of each individual flask including cap and septum is measured. The exact substrate amount is transferred to the bottles according to the experimental design (usually 80 to 200 mg oDM). The preparation of inoculum depends on the source and on the experimental design. As inoculum, an anaerobic culture according VDI 4630, from industrial biogas plants, sludge from waste water treatment plants or own lab fermentation processes with dry matter contents of less than 4% and organic dry matter contents of 50 - 80% (of DM) can be used.

[0065] The necessary amount of inoculum is collected and stored in a Woulf's bottle at 39°C. For the set-up of the batch experiment, fermentation vessels are filled with 15 ml inoculum and all additives of fixed volumes. Dosage of the inoculum is made with a Watson-Marlow-dosage pump 520 DIL/350. During manipulation, i.e. harvest and dosage, the inoculum is floated with collected biogas from other fermentations. Before closing the vessels, they are flushed with N₂ for 20 seconds. Then they are capped and closed with a special device (Fa. CS-Chromatographie GmbH, Langerwehe). All bottles are mixed vigorously in order to suspend insoluble substrates. The total weight of each bottle is determined.

[0066] Fermentation is started by transferring the flasks to a 39°C water bath. Gas pressure in the headspace of each replicate is measured after one hour. These values represent start pressure of fermentation and all further gas values are cumulated to this first value. Gas pressure measurement is carried out with a Digital Manometer Kobold HND-P236. For gas pressure measurements, a needle (0,45 x 25 mm, 26 G x 1 ", Fa. B.Braun, Melsungen AG), which is connected to the manometer via Luer lock, is pierced through the septum. The gas pressure of each replicate is stored and data is transferred to a computer for analysis. After measuring and data storage, the gas of all vessels is released by introducing a needle into the septum of the vessel. After 5 hours of incubation, the second pressure measurement is carried. Then, the gas pressure is measured once a day, always at the same time to ensure 24 h intervals. Every day, at least one hour before starting measurements, vessels are shaken. The interval of gas measurements may be stretched to two or more days, if the pressure increase per day is lower than 100 mbar.

[0067] Output of these tests are (a) gas formation curves over normally 21 days (mean values), (b) gas formation velocity (Nml gas per day or per hour), (c) relative gas formation (compared to corresponding control), (d) statistical analysis including MV; SD; confidence interval and if necessary T-Test of two groups of values, (e) gas yields (value accepted until daily gas production is lower than 1% of cumulated gas)

Example 2: Anaerobic degradation of maize and other whole-plant silages using enzyme additives, which have proteolytic and carbohydrolytic activities (Fig. 1)

[0068] In the described experiment, corn, triticale and grass silage were incubated with an enzyme preparation containing protease and amylase activities. These batch fermentations were inoculated with a microbial community taken from a lab fermenter fed with corn silage. On all tested substrates, a significant enzyme effect was shown. For corn silage, the gas yield was increased by roughly 20% compared to the negative control during the first 10 days of fermentation. The gas yield from triticale whole-grain-silage was increased by up to 15% and the gas yield from grass silage by roughly 20% during the first 7 days of fermentation. The culture, which was nitrogen-limited, produced biogas at a significantly faster rate from all substrates, if the enzyme preparation was added.

Example 3: Anaerobic degradation of maize silage and sorghum using enzyme additives, which have proteolytic and carbohydrolytic activities (Fig. 2)

[0069] In the described experiment, corn silage and sorghum silage (50/50% w/w) were incubated with an enzyme preparation containing protease and cellulase activities. These batch fermentations were inoculated with industrial waste water.

[0070] Combined cellulase-protease preparations and single protease addition elevated the biogas production compared to the addition of the cellulase containing additive during the first four days of fermentation. Thereafter, the combined preparation showed higher gas production than each of the single enzymes. The observed increase of the gas yield ranged between 6-8% during the first 6 days of fermentation. The reason for this observation could be that the microbial consortium was not only energy-limited (carbon source), but also limited in nitrogen. Only if both limitations are addressed, more gas is produced. Hence, the combined application of preparations with protease and carbohydrase activities shows effects superior to the application of enzyme preparations featuring only one of these lead activities.

Example 4: Anaerobic degradation of maize silage using enzyme preparations, which contain different carbohydrase to protease ratios (Fig. 3)

[0071] The beneficial effect of the combined administration of a carbohydrase and a protease was observed over a wide range of dosages. Experiments showed that enzyme mixtures composed of a carbohydrase and a protease in ratios of 20:1 to 1:1 had significant effects on the biogas production. The increase of biogas after one week of incubation was 5 % for the carbohydrase alone. Preparation with the combined lead activities yielded increases of 38 % (c:p=1:1), 26 % (c:p=2:1), 17 % (c:p=4:1) and 8 % (c:p=20:1).

Legend of the figures

[0072] 

Figure 1: Degradation of corn silage in batch fermentations.
The observed effect is attributed to the enzyme preparation only. A partial effect of the enzymes' stabilizing agent can be excluded as the negative control, for which enzyme stabilizer was used, did not influence the gas yield.

Figure 2: Degradation of corn and sorghum silage in batch fermentations.
The influence of the combined carbohydrase and protease preparation on the degradation of a recalcitrant substrate is shown.

Figure 3: Degradation of corn silage in batch fermentation.
The influence of the preparation with combined lead activities is shown. In order to illustrate the positive effects, carbohydrase:protease ratios ranging from 1:1 to 20:1 were tested.

Claims

1. A method for improving digestibility of substrates for anaerobic digesters, which method comprise treating a substrate, especially a substrate for biogas production, source with an efficient amount of one or more proteolytic enzymes in combination with at least one carbohydrase, wherein the one or more proteolytic enzyme is an acid stable serine protease derived from Nocardiopsis dassonvillei subsp. dassonvillei DSM 43235 (A1918L1), Nocardiopsis prasina DSM 15649 (NN018335L1), Nocardiopsis prasina (previously alba) DSM 14010 (NN18140L1), Nocardiopsis sp. DSM 16424 (NN018704L2), Nocardiopsis alkaliphila DSM 44657 (NN019340L2) and Nocardiopsis lucentensis DSM 44048 (NN019002L2), as well as homologous proteases.

2. Method of claim 1, wherein the substrate is a substrate for biogas production.

3. Method of claim 2, wherein the substrate comprises an energy plant, such as maize or maize silage.

4. Method of claim 2, wherein the substrate comprises, liquid manure, agricultural byproducts or organic waste.

5. Method of claim 1, wherein the proteolytic enzyme is derived from Nocardiopsis dassonvillei subsp. dassonvillei DSM 43235 (A1918L1).

6. Method of claim 1, wherein the at least one carbohydrase is an amylase or a cellulase.

7. Method of claim 1, wherein the at least one carbohydrase is an enzyme mixture comprising at least two enzymes selected from the group consisting of beta-glucanases, xyloglucanases, xylanases, amylases and pectinases.

8. Method of claim 1, wherein the relation of carbohydrase to protease in enzyme mixture can range from 1:1 to 20:1.

9. Method of claim 8, wherein the relation of carbohydrase to protease in enzyme mixture can range from 2:1 to 5:1.

10. Method of claim 1, wherein the enzyme mixture is used in an amount of 0.01 g to 10.0 g per kg substrate (10 - 10000 ppm).

11. Method of claim 1, wherein the enzyme mixture is used in an amount of 0.1 g to 1.0 g per kg substrate.

12. Method of all preceding claims, wherein the reactor temperature lies above 20°C and below 70°C, preferably between 35°C and 42°C.

13. Method of all preceding claims, wherein the pH of the biogas fermenter lies above 4.5 and below 9.0.

14. Method of all preceding claims, wherein the pH of the biogas fermenter lies between 6.7 and 7.5.

15. Method of all preceding claims, wherein the preparation is administered regularly shortly after or preferably simultaneously to the feeding of the substrate.

Amended claims

Amended claims in accordance with Rule 137(2) EPC.

1. A method for enhancing the digestibility of substrates for biogas production in anaerobic digesters, which comprises treating a substrate, with an efficient amount of one or more proteolytic enzymes alone or in combination with at least one carbohydrase, wherein the one or more proteolytic enzyme is an acid stable serine protease derived from Nocardiopsis dassonvillei subsp. dassonvillei DSM 43235, Nocardiopsis prasina DSM 15649, Nocardiopsis prasina (previously alba) DSM 14010, Nocardiopsis sp. DSM 16424, Nocardiopsis alkaliphila DSM 44657 and Nocardiopsis lucentensis DSM 44048, as well as homologous proteases.

2. Method of claim 1, wherein the substrate comprises plant material, such as maize, maize silage, corn silage, grass silage, triticale silage and/or other whole plant silage.

3. Method of claim 1, wherein the substrate comprises, liquid manure, agricultural byproducts or organic waste.

4. Method of claim 1, wherein the proteolytic enzyme is derived from Nocardiopsis dassonvillei subsp. dassonvillei DSM 43235.

5. Method of claim 1, wherein at least one carbohydrase is an amylase or a cellulase.

6. Method of claim 1, wherein the at least one carbohydrase is an beta-glucanase or a xylanase.

7. Method of claim 1, wherein the at least one carbohydrase is an enzyme mixture comprising at least two enzymes selected from the group consisting of beta-glucanases, xyloglucanases, xylanases, amylases and pectinases.

8. Method of claim 1, wherein the relation of carbohydrase to protease in enzyme mixture can range from 1:1 to 20:1.

9. Method of claim 8, wherein the relation of carbohydrase to protease in enzyme mixture can range from 2:1 to 5:1.

10. Method of claim 1, wherein the enzyme mixture is used in an amount of 0.01 g to 10.0 g per kg substrate (10 - 10000 ppm).

11. Method of claim 1, wherein the enzyme mixture is used in an amount of 0.1 g to 1.0 g per kg substrate.

12. Method of all preceding claims, wherein the reactor temperature lies above 20°C and below 70°C, preferably between 35°C and 42°C.

13. Method of all preceding claims, wherein the pH of the biogas fermenter lies above 4.5 and below 9.0.

14. Method of all preceding claims, wherein the pH of the biogas fermenter lies between 6.7 and 7.5.

15. Method of all preceding claims, wherein the one or more proteolytic enzymes alone or in combination with at least one carbohydrase are added before, after or preferably simultaneously with the substrate to the fermenter.

Drawing